EARTHMOVING # FORESTRY MATERIAL HANDLING EQUIPMENT Electric System Service Training Text Company LLC WHL9020-0W_ ° ay “ est icgrs mataye siitosig ixeT pniniesT soivise 344 ynnqimnod GD FOSHO IHW | eS ee tt ES ke eo ee ee ee ee PA ee q-Table of Contents 1. Electrical Equipment Arrangement Drawing General View Operator's Cab: 2, Electric Circuit Diagram: 3. Explanation of Functions 1) Outline - + 2) Function System Diagram ~ @ Engine Contr @ Pump Control Boom Lowering Speed Regulation @ Shockless Boom Starting proseure asain Syste (©3-Spood Travel and Max. Flow Cut @ SoftHard Switeh ® Power Supply Cut Delay « © Swing Brake/Swing Lock @ Lever Lock @ Travel Waring @ Power Transistor Protection: @ Monitor Display: - 4, Selt-check '5, Electric Equipment Measuring Method 6. Throttle Motor Replacement and Automatic Adjustment ~~ 1) Throttle Motor and Throttle Link Replacement Throttle Link Replacement ~~~ 2) Automatic Adjustment 7. Installation of Revolution Sensor: 8. Troubleshoot 1) Troubleshoot 2) Checking Before Diagnosis 3) Failure Diagnosis Process: 4) How to Read Flow Chart: 5) Engine Emergency Stop: 6) Refuel 7) Refill Coolant 8) Replenish Battery Fluid 9) Air Cleaner Clogged 10) Engine Oil Pressure Down 11) Engine Filter Clogged 12) Over Heat 15) Battory Gharging Deficient == 14) Electrical System Abnormaites: 18) Trouble Description (Trouble No. 11) =~ 16) Trouble Description (Trouble No. 12) 17) Sensor Resistance Value 45-46 9-52, 53-55 56-67 68. 68-69 70-71 2 87-89 90 1 +92,zin@inod to sideT tech rane A tee ap ar) crest wD ete 2 UAT Ns eg More a saekaen 4 ewe AL pat bee ie | arent ree 6 sonnei aes poet FtR Fk Bae e = ” x «i + ish te. 3 oF weer Aa “ be Deere rent hs ahem ah ata aka ee ae? pein They 1 Mya are # sage ey 7k sect ror Merur 1A sae ttt 31 mete mats ve tele Te cmt semua nim See ot ote ee RGOSRGSEST i ho St to me Be is 3 = os1. Electrical Equipment Arrangement Drawing General View. Operator’s Cab_ General View Vi $H100/120General View $H200/2202. Electric Circuit Diagramyarn re ro bs eR oe sr ee Se ee eee “ m o £ o 9 & 2 2 & o 2 &3. Explanation of Functions 4) Outline os soo . cvtemeen @ 2) Function System Diagram. 7 67 @ Engine Control. Pecbdnesseneeee 8-22 @ Pump Control . oe esses 29-25 @ Boom Lowering Speed Regulation 26 @ Shockless Boom Starting vom 21-28 © Pressure Raising System - 29-31 @ 3-Speed Travel and Max. Flow Cut 32-35 @ Soft/Hard Switch.» een a 36 Power Supply Cut Delay. 37-38 © Swing Brake/Swing Lock “ 39-44 @ Lever Lock a, 45-46 @ Travel Warning soa a7 @® Power Transistor Protection ---. 48 ® Monitor Display- . ee AD1) Outline @ Engine Control (1) Basic Operation of Engine Control (2) Function Explanation Cen] ‘Wore | ‘Asiight ference of APM | between each mode is con- rolled by high precision, Difference of ling RPM in ne revolatons © | nae SSjusemert © [ating controt teach separate machine isreg- | —-} Usted. [One touch/auto idle RPM is reduced tothe machine's org- inal ding HP machine Stored data, Destination Country Model Name 'S Mode Revolutions Mode Revolutions Memorize the values peculiar to each {Giore in nonvolatile ROM.) | fale Mode Revolutions» soOrpm & ‘Japan SHz00 H-100rpm_ HE200%pm_ ‘An oporator can adlust engine PM by one-touch Engine APM and idle RPM by throttle ‘olume are selected with knob suite [When forgetting to set to 1d- fing, itis sett wing status fautSmaticaly. fis reset with a fenob sven, when auto la is selected, automat Italy decreased to idle RPM 15 sac- ‘nd® after levers put into neutral Ditference in engine RPM is @ [Engine automatic warm-up @ [Breaker revciution contol |——|fo the RPM that a breaker matic adjustment Engine RPM is changed per mode [according to the data gained by auto- Roxon onratereach |__| PUSS ose or | {rd ne | [Re nodlted moos (aay aepprig ova eater] - odal, tchanges automaticaly requires. “Turn on pressure switch ted on breaker pit line and RPMA is turned into eottng value. (Store by diferent [procedure in nonvolatile ROM.) [When starting an engine, it itis Deieaiion of thratle motor assembly defect @ | Engine reverse rotation pre- ‘oak warming up fs begun sciemateany °° ‘Increases RPM gradually from start: Ing, and warms Up & circulates iubr fcaling ol around the engine.) Detects assembly in which throttle motor damage is highly ossible and alarm fe given. aly, motor stops. Monitors for abnormality in srk movement of imi swatch for throttle motor reference postion. tan abrior- 4 Rooverse rotation of an engine vention Is detected, andis stopped. | —] (ere engine is stopped. ‘gine rotation stablizes, en. gir presaur sich is monored HON status continues for 3 seconds,[ee @[Pume contrat lation @ |Proseure raising @ [aor owering speed regu: @ [Boom starting shockiess i [iver] (| Italso decreases boom lowering system Pump control depends on work such 28 large working load, good fuel eonomy and fine operation, Speed whichis @ Sa weg fakin UE -— ‘Supply curtentto electio- magnetic proportional Sure redueing valve b ump Is controller. When UF mode is selected a Boom lowering stroke of CNV is roguiated. Prevents the shock phenomenon oc- {cure when boom lowering operation is |__| ‘Saree. Wen starting fora vary shor ime negative contol signal 0 /apump, boom towering delays discharge quantity, @ [speed Waveland max. flow eut @| swing brakerewi | Lever tock Power increased when more force Is. | [Sesired, of during ravel or Ranging operations, (igh, midale or ow speed travel oper] — | alloy obtained by stop switch, More over performance improved during F |—~) rode, [Set main rliet as 2 step relief, [and ineroase relief pressure as evessary, Sat aval ot 102-9608, ive typeton tresicing "| thax discharge qeantiy by | ump, and cosine a8 neces: Bay: J ing lock | ie ey ej ON and operation besides Swing 0% When st operation is selected,” shock relieved at when boom arid farm stop. When hard operation's |—| Selected, itis possible to turn of the [eushion, J Operation on or off of cushion valve is input from switch pan a [peas paramos ata ty onieh [OFF (engine stop contol) Power supply. eng bake: Sing | Teaver warning ® | Power transistor protection | Monitor eisplay [Unies in stable condition, getting on and of is impossible. Avid extching cn over geting on ad ft Posse to shot of mmasiatoyin an emergency ‘OFF and lock SW ON. 100% swing ok on 0% (release) ‘Aer te Key switch is OFF, ni pate relay isc of ime is delayed. By instaling a pressure red- Gate lock interlocked with shut Lover tock switen during taveling i power transistor output of controler | s\shorted, the controller's protected. ‘Warning glvan to people in the area ‘Buzzor (STD) is operated by twavel pressure switch By instaling an overcurrent [sensing creuit within the con- roles, output destination shorts, power transistor output J Radiator water temperature Hydrate oll temperature Fuel remaining Waring display lis stopped. off | Tk up inertocked with shut off |@ Engine Control (1) Basic Operation of Engine Control Like the existing F2 series, engine throttle control is done with throttle motor (electric motor) CQ votage 9 Wea) rq Throttle volume Controter Motor driver Trrotie moter Engine throttle ‘Stepping motors used on a throttle motor of recent PAX series. ‘Stepping motor ‘A stepping motor is the motor that rotates when synchronization is turned into & pulse signal from a pulse oscillator. When using a stepping motor, the pulse oscillator is what determines rotational speed and a rotation degree. The dtiver circuit is what switches in order that the current in the collin the stepping motor. Is changed. Itis necessary to amply the signal in order to drive the stepping motor: (cesar (EEE i {ge pet —— | Sao ae | Pulse oscillator determines rotation degree and rotational speed of a stepping motor. A stepping motor rotates synchro- nizing with the pulse signal which is turned an oscil- lation from this circuit. Rotation degree depends on the pulse number. | This circuit is used to make the pulse signal that Driver circuit (driver) Driver circuit of a stepping motor consists of the logical section which forms and distributes a pulse signal from an oscillator. And amp section which amplifies and supplies to a motor. In other words, itis a circuit sending current by the decided sequence to the motor coil at the pulse train output from an oscillator. This “excitation method” excites the coil by the decided order.‘Stepping motor pr ple (if 1-phase on drive) A phase fe fisf—ex Stator i ee FT mE A case x[ bef le a G6 a > @ 2) safe] Se ° LL. L 7 v) ale a ® o | -P <] -#[2 oter ‘An excitation phase of A phase, B phase and C phase are rolled on stator. When pulse enters A phase, rotor is in (1) condition and A-a, A’-c are profitable. Pulse of A phase breaks next, and when pulse of B phase enters, B-b, B'-d are profitable, and it results in (2) ‘condition. A rotor rotates in this condition counterclockwise. (A> B > C). When pulse is sent in the: order of C-> B-» A, a rotor rotates clockwise. Lt switch Power shaft —Reduction gears Drain hose ‘Stepping motor ‘Throttle Motor StructureEngine throttle related circuit diagram a - S53 wz | Fc od Tite a al wee no roan : 3 Vague surterctockatet oft iret 1 At |s | tt 2 % ! it i 1 Mt I scone be 1 ht . tanta of 4 “ote motor iil pt sero HEEEED 2eE bre Bt Convener py 8 ‘Shut down, “Motor driver Key switch ON] Fullside Stop side ‘Limit switeh (Clockwise) Throtle motor (0 detected) “Throtte mater (Stops at pulse position of trotle volume) A signal enters CN2-9 of a controller and ACC of a motor driver from ACC of a key switch. (24V) The controller and the driver judge that the key switch is ON when this signal enters. The controller sends clockwise rotation instruction (CN8-2) to the driver, and the driver ‘sends pulse clockwise rotation (ABA1B!) to the throttle motor. When rotating fully clockwise, the limit switch of clockwise direction (stop side) is pressed. With the signal of this limit switch entering the controller (CN4-9) through the driver. 0 point detection of a throttle ‘motor is performed. (O pulse) ‘After 0 point detection operation, in order for a controller to confirm throttle volume position, voltage (CN10-2) from throttie volume: is converted to pulse number. To rotate to the position where throttle volume requires it, instruction (CN8-4) of counterclockwise revolution is sent from the controller, and the driver sends pulse of counterclockwise side to a motor. Pulse is sent to controller (CN4~1) at the same time. When demanded pulse of throttle volume (pulse which is converted by controller voltage from throttle volume) becomes equal to the the pulse which is sent to controller as a feed back signal from driver, the ‘motor will stop rotating ~w-[Revolution Increase Throtle motor PUL 2012 op When throttle volume rotates clockwise, the voltage of throttle input increases. For this reason, the controller sends instruction of counter- Clockwise revolution to the driver. The driver sends pulse of counter- clockwise direction to the throttle motor. At the same time it also ‘sends pulse to the controller. ‘When the pulse number which is converted from voltage of throttle volume becomes equal with the pulse which is fed back to the controller, the command from the controller stops, and the throttle ‘motor stops. The lower side, compares pulse number and stops at throttle volume needed position. s 3 [Spring deflection range rau et tating 27 Spring detection range umtsw “Oo ‘ON, Trrotle motor Throttle volume ‘Stop side I — stor FF) Throttle volume 2. Pulse — av Voltage ‘When turning the key switch fo OFF, a signal of ACC line of the motor diver switches to OFF. When this signal is turned OFF, the driver sends the pulse to the throttle motor unt the limit switch of clockwise direction turns ON. The governor lever moves on the stop side, and the engine stops. ‘The stop motor also operates at the same time in another circuit and the fuel cut lever is moved to the stop side. neROTATION INSTRUCTION OF A CONTROLLER 25 | cow (Counterciockwise) fi bel es CW (Clockwise) ve Driver Doreen Dew ae 00 nm @ After key switch ON When the transistor on the CW side of the controller is turned ON, 5V from a river circuit drops to ground. For this reason, CW line is OV and CCW line is 5V at the driver side. “| cow icounterciocvise) F CW (Clockwise) Contoller Dever <=) Reatonistacon elon decton se 7°” | cow (counterclockwise) |g” |e @ After CW side limit switch ON ‘cw iCockwisey __|§ le The contolor tums OFF the vansstor aK i con the CW side, and turns ON a COW ‘side on the driver side, CW line is 5V and COW side is OV. Controller Driver CoWoV "| >) caoninstruton of counterclockwise revolutions 9 cWSV @ The stop status in volume position cowsy CCW and CW of transistor areturned OFF, | Gey Motor rotation stops. and both lines at the driver side are SV. =ActivAtion of stop motor Shut down ‘shut down A Key Switch ON ‘2! folay 2 By power supply of key switch ON, H| the excitation col of relay 2 works relay changes to the lower side. Switch x, Stop motor shite Operator Emergeney , _oeide see tp——— ae eo Th, [The stop motor and the Fuse switch within the motor av —] are interlocked. When a nina motor moves tothe oper- cone ation side, the switch 2 | Moor er switches to the lower tI side, and the power sup ply of the motor turns Controlter OFF and stops. When key switch is ON nN swith Stop motor Shutcown Shut down relay t relay 2 vor B Key Switch OFF 3 fl ail). SEE ‘Stop motor Operator ‘ide emexganey———— |} as ey step ben | ~S , 4 The stop motor rotates Stop side Fuse oy and when the motor cr moves to the stop side, “len2 the switch switches to 9 eh the upper side, and the power supply of a motor tums OFF and_ stops. ‘The engine stops. ‘Switch () ‘Stop motor Gontoter When key switch is OFF (Engine stop) Stop side FP© Emergency stop button ON Shutdown Shutdown volt ray? sey vith on if rat ae stop motor creo tO sop ade < ©) ZA, — » Fuse ae ‘The coil of relay 1 is excited when the = emergency stop buton is pressed when the | Motor ever key switoh is ON (previous section A), and the relay switch tums on the lower side Since the excitation votage to relay 2 runs Conor \ const stop" Input signal —14— out, the relay switch is returned to the upper side. The power supply circuit of the motor is formed, rotates, tums to the stop side, and the engine stops. ‘The motor switch is switched to upper side, and it stops. ‘Stop motor ‘Switch stop side MRedundancy (Back-up) throttle control Manu Fuse Back-up SW | throtte SW aes Ha lw vec |b Ir only | fs ee i i wrelte 7 it | N it nals PPL apes i i ag ‘Shut down, Motor driver rolay 1 When throttle control cannot be done due to controller defect, press the redundancy switch, and throttle ccontrol is done with manual throttle button (UP, down). ‘When pressing a redundancy switch, control power supply of controller goes OFF, and the circuit of manual throttle is formed at the same time, There is a signal of SV on the motor driver side. When pressing manual throttle, instruction of a rotational direction is sent to a motor driver (same method as in previous section “rotation instruction of the controller’). (While pressing the button, the motor operates). To stop engine, manual throtle is pressed to the DOWN side, or the key switch is turned OFF. While running the engine, when the redundancy switch is turned OFF (normal status), the engine is, stopped. (When redundancy shifts to normal status, 0 position of throttle motor is detected.) -16-@ Engine Automatic Adjustment ‘There is a wide variation in engine RPM depending on each machine. To finely control in each mode (or to eliminate wide variation in iding RPM, store the setting RPM to the controller at an early stage. This is called automatic adjustment. ‘When replacing a new controller and a throttle motor or adjusting and replacing control link between the engine and throttle motors, automatic adjustment must be done. FULL : H MODE MAX Revolutions RS: S MODE MAX Revolutions Engine revolution RL: L MODE MAX Revolutions 29) RY IDLE Revolutions spring detection rang ‘oe | ae oa | 200 200 Sofas T | Throttie motor (Angle) Tp pe adh, Throttle ulse) HGH FL 7S Tang Thretle motor (Pulse) ‘Automatic adjustment explanation 1) Engine RPM at the time of full throttle: FULL is read. (Hmode MAX) 2) While monitoring engine RPM, RPM is decreased automatically RS=FULL-Dt RL=FULL-D2 Fielding revolutions(SH100/120=980rpm, SH20/220=800rpm) When each RPM is reached, position of a throttle motor, PS, PL and Pl are read. 3) Store the read PS, PL and PI to the controller. Refer to adjustment instructions for automatic adjustment method. —16—© Idling Controt Controller OnetouedAua change swich Conte fro] Gh wr |E er [ti YT * z -—) Dorm race a : INS z Uopor pot pressure suten (P) dale Travel plotreenrs etch e sNontor knob switch Changed to one-touch idle sta- tus by key switch ON and a lamp lights up in the change switch ® ‘One-touch idle operation is possible when in one-touch id key ante) mt ling regardless of whether the on| pilot pressure switchs of IN2, tame IN3, IN4 is ON or OFF One-touch ile ¢ knob switch ® By pressing the change switch ‘and when the lamp goes off, it isin the auto idle. ‘When changing to idling auto- matically, with all IN2, IN3, IN4 In| atches tried’ OFF i oe- | crease to idle after 15 seconds. Ph we me Engine revolution Montor | when increasing, the operation Montara aa gS ‘ Seto ors is posse by ony pressing the Sats, smo saten regardless. of — ~~ — “W——_——- ON/OFF of the switchs of IN2, ® ® IN, NA ‘When the engine key is tured OFF during auto idle, and if tis tumed on again, auto idle is released, and results in one-touch idle status. breaker RPM. Refer to automatic adjustment section regarding how to set the of breaker RPM, the pedal is stepped on, breaker -1-© Engine Automatic Warm-up Throt mt volume Controller Fe Water temperature sensor oC Upper pilot pressure switch Lower pilot pressure swith One: Yenob switch Driver Throtle motor Monitor ‘Auto warm-up | os Conditions for automatic ey —_ yf] warming UP 1500, 1} 1.Water temperature is | less than 50°C 1200 2. Piot preseure sich of Torta voame| 1 ee [- upper is turned OFF. exe {attachment is not oper aing) {out [ ~ 3. Pilot pressure switch of eke 5 lower is turned OFF nite ssn (raves not operating) pee we 4.One-ouch aia tuned oF sesso 1500 / _ 5:12 eoconds ater engine Approx. 1980) | When all the above condi 4200 / tions are satisfied, auto- matic warming up is ais + —13 performed, stats sminures Jminutes, {tis in throttle volume posi- START tion unless all above condi- tions are met.© Detection of Throttle Motor Assembly Defect (Out-of-step) What is being out-of-step When the pulse signal cannot be followed from the driver, and deviates from regular rotation Possible Factors _1. if the adjusting sorew of the throttle fink is loosened, and the length of the tink is changed more than the deflection of the spring 2. When the link of spring starts and is not elastic. 2. Itt he key switch is ON (also during running), and the throttle motor rotates by abnormal external force, and it shifts tothe stop position. Cutof step detection (safety device works to protect throttle moter from breakage when above problem occurs). 1. Alter the key switch is ON, the limit switch of clockwise direction (stop side) is, not turned on after 2 seconds. 2. After the key is switch ON, the clockwise limit switch is turned on and afterward even though the key switch is not turned OFF or the emergency stop switch is not pressed, the clockwise limit switch is tured ON again. 4 ‘Stops the drive of the throttle motor, and “electric system abnormality” is displayed on the message and “0000" is displayed on the clock f ectc system abromaiy osu] 00 00 ey Sa Check the throttle link relation first if the above is displayed. Reter to throttle link installation procedures. -a-1 Reverse Rotation Prevention It the engine performs reverse rotation, this featar stops the engine in order to protect it and the hydraulic circuit. ‘When the engine changes to reverse rotation from forward rotation, the pressure of the engine oil decreases. Then 12 seconds after engine has been started, the pressure switch turns on for 3 ‘seconds and the throttle motor is moved to the engine stop position. Controller Driver am Throttle motor il pressure switch t i t—) oN Monitor hs = ==) -2-@ Pump Control constr { “ Electro-magnetic proportional oe change esos easconvave Nose change Sa re af os s| o> | oo | elles £ Upper side + Pree Sy | revels oh T Pressure S)W : | Enger revoiuion sensor ss c (*) | Thro rotor Thre vine i astzs Z Wor ver Horsepower Torque it n Ts-0.9T resort Horsepower ts 4 Flow |—~ *s__ Eleette current value * max ievolation Target (At H mode max. revolutions) ‘S$ MODE initial value, LMODE initial value. (Same as also F mode) Itengine RPM less than 1200rpm : same as L MODE irrespective of mode selection, ‘At the time of L and F MODE travel (upper side pressure SW OFF, travel pressure SW ON): itis same ‘as $ MODE. (Purpose; travel smoothness protection) Pressure when pump torque amounts to 90% of engine target torque T, IS is given by a constant as the when pump torque amounts to 70% of engine target torque T, IL is given by a constant as the _Pump controls same as Fl2 method. Current is sent o electromagnetic proportional pressure reducing valve of the pump in each mode, and controls flow rate based on this. In the H mode, RPM of the engine is loaded, and current value is changed, utilizes maximum output of the engine. , L, F made is current value fixation. Current value of each mode Values in chart below are design median (ma) Mode | H s 5 [Machine Typ IMAX ‘san | F ‘sH100 425 245 250: 20 o eu 385 245 t 7 t | snovo wo) a 305 20 ' | sizzo 20 x 020 1 ft —m—Flow Chart] Pump Controt OFF Putoutaierence beeen to ‘APM ‘set Co -— Determine Inereaseldecrease value of pump | torque ——_l Convert toraue Value to current value | For L made Fixed current value For S mode Foxed current value H mode current set value Tonext process@ Boom Lowering Speed Regulation Circuit Diagram’ Mode change SW Contotor s ws ([ Wl we [F ul wa |F F Na Time Chart| on) Key switen 1 er jee] Contr! valve ‘boom spoo! (co) Solenoid valve > Z ect naw! ou = wae om - | i i i i | out oy} 2a T ——— MoDe s | 4 L for | s Flow Chart] Boom Lowering Speed Regulation More than ‘400rpm No is engine running? — << Mode check > — | 1 __ ie awa || cmon | Lo ‘Tonext process: + Spoed regulation of boom lowering is activated only in L, F mode. ‘In changing to L, F mode, a transistor in the controller turns ON, and a solenoid valve switches. Pilot pressure is sent on the raising side of boom ‘spool of the control valve, and the movement of spool is regulated. ~26—® Shockless Boom Starting Circuit Diagram Solenoid valve Boom lowering wi | E av] “Sr Plot pressure SW our Travel ae t Pilot pressure SW al Negative contol signal woe 2 yy / | / aw | out m4 m1 wv | TS _| evontong raven and too O.ASEC O.ASEC ©.4SEC —_jowering swithes are ON, pulse to solenoid vaive does nat go ON. ‘When pressure S/W of boom lowering turns ON, the solenoid valve switches for 0.4 sec, and pilot pressure is sent to the negative control signal port of the pump, and it becomes negative control flow rate If travel + boom lowering is operated, boom start up shockless is not performed, and this is the reason to detect pilot pressure of travel. (travel smoothness improvement) arFlow Chart| Shockless Boom Starting No is engine running? Yes No ‘STEPS-0 HON gore than ‘590. fudget YES oben No oN Fravel pressure SW>— Yes OFF oN, No OFF ‘Boom pressure SW. (On for 0.4 sec.? Boom a OFF Yes ON ‘STEPS-0 set STEPS=2 set STEP3=1 set STEPS=0 set Timer set Count cancel Timer clear (04 sec) timer clear Output OFF Output ON Output OFF ‘To next process© Pressure Raising System (One-toutch digging force UP, Travel power UP) Main ratetvatvel es Panel switch Controller One-touch digging force UP switch 4v| soled yao | but of FEV fe ‘Travel pressure ‘alten 3 wale Digging ree uP r U H+ moae Timo Chan ; sesamin SB . — Monier ésolay SST DST a = ® When one-touch digging force UP switch is turned ON (INS), the signal enters the controller through timer in the panel switch (for 8 sec). 24V is output to a solenoid valve from the controller, and the solenoid valve switches. Pilot pressure enters the rain relief valve, and pressure setting increases. ING switches for 8 seconds after one-touch digging force UP switch ON. “One-touch digging force UP" is displayed on the monitor at the same time. Even if the one-touch digging force UP switch is pressed for a long time, pressure setting increases only for 8 seconds. @When the travel pressure switch is tumed on, 24V is output to solenoid valve and pressure setting increases. itincreases while travel pressure switch is ON. (No timer setting) itis not displayed on the monitor. In turning ON one-touch digging force UP switch in this condition, digging force UP appears fon the monitor for 8 seconds. ‘Though it is in travel + altachment condition (one-touch digging force UP switch OFF) setting pressure setting increases, and the pressure setting of the attachment also increases its pressure,Key anten wep este w sees pose ——___freste~_ ™ 6p wt 3} 1 oor ow a | @Even though one-touch digging force UP switch is pressed, the voltage is not output to the solenoid valve, and pressure up is not performed. Pressure up is performed in H, S mode when travel pressure switch is ON. Pressure up is performed also in travel + attachment. F Mode ‘When set in F mode, voltage is output to the solenoid valve regardiess of one-touch digging force UP, and results in pressure up condition, (F mode means fine mode, and it increases hanging force during hanging operations.) Digging force UP Result 1) Pressure up is performed when travel lever moved. (Itis not displayed on monitor.) 2) Because pressure increase in travel + attachment, even though the switch of digging force UP is not pressed, pressure of an attachment increases. 3) H, S, F mode : pressure increases during attachment only operation However, in H, S mode digging force UP switch must be pressed. .. . tis displayed on the monitor. In F mode, pressure always increases for improvernent of hanging work abilly. . .. It is not displayed on the monitor.Flow Chart] Pressure Raising System Initial: STEP=0 no. A travel pressure switch has priory. (engine running?>—> Yes on Fave rossure OFF Mode check >] HS ‘Switch panel function | Yes, STEP-02 No No, sTeP1? > — | STEP=3 set ves "Gsecy" Fessute raisiigs, OFF _ Si = on \| STEP-2 ot - 1 {I | sree steps set | | J = Ld Timer cleat | | \ __ ——_| To next process —a-© 3-Speed Travel and Max. Flow Cut Switch panel __Controler areal Travel change switch IN 5 12 L nv Spwiteh 5 7 ‘ave pressu ee witch Upper pressure | wo SL Travel motor | change solenoid V out} | Max. flow cut solenoid V ov Monitor display | @ Traveling at middie speed (always middle speed when key switch ON) Even though travel and upper pressure SAW turns ON no output to both solenoid V. aval motor swash plate Tow side Pump : standard Tavolng a tigh speed (pressing INS switeh once wen traveling at mide speed, t shits to high speed.) ‘Tho travel motor switching solenoid valve turns ON, and swash plate ofthe motor shits to upper side. Travel motor swash plate ; upper sd @ Traveling at low speed (pressing IN5 switch once wen traveling at high speed, it shits to low speed) When a pressure switch of travel changes, the max. fiow rate cut solenoid valve turns ON, and Q is cut. Swash plate ofthe motor shits to lower side. ump = Q cul Even though upper pressure SW is turned on, max. flow rate cut solenoid V does not tum on, and is not Qeut V1 Teavet sor, | $0L malo | Ox | OFF soienoavave* fini ft for travel change ist ow bein See [So. ] sou. { Pane ‘ON | OFF. vl Srersteewnset [ca [sma foutz © DAtmmiddle speed travel Travel motor swash plate : low side Pump : standard @ Athigh speed travel Travel motor swash plate : upper side @Atlow speed travel Pump -Q cut rn as in S mode. |m3 Travel change N 4 ‘witch INS pat ‘Travel pressure ‘witch Upper pressure j Uio ‘Swe ‘Travel motor change desk} eee | a4 —— || LPamp standard at wavel single operation — At fax, tow eat Monitor 5 1 tT Inv & 1 éeplay |? 1 ! Co tess rcs) @Atmiddle speed travel _| Qeutis done by F mode using the ON signal of upper pressure SAW for Travel motor swash plate: low side Pump: standard @Athigh speed travel ‘Travel motor swash plate upper side @Atlow speed travel Pump :eul the frst time. OA‘ middle speed travel Travel only operation. ——y—Travel motor swash plate: low side L_Pump: standard | Upper oniy operation | |_pump :@ cut ‘Travel + upper combined—y—Travel motor swash plate: low side | pump :@eut @Athigh speed travel | © Travel only operation. —)—Travel motor swash plate: upperside (pump: standara Upper only operation. — Lpump : out Travel + upper combined —) Pump : Q cut @Atlow speed travel ‘Travel only operation. — “Travel motor swash plate: low side Pump : Qeut {Upper only operation — |_Pump : Q cut ‘Travel + upper combined~—-—Travel motor swash plate: low side sump : Qeut 3Relation of Travel Mode and Motor Swash Plate, Pump Quantity Cut Relation of Travel Mode and Motor Swash towside | tow side | pate, Pump Quantity Cut = High Speed |Midale speed] Low speed ‘Travel motor | Upper side Pump output = ns - ee Standard | Standard | Qeut Work made is independent. However, since MAX. rotation changes by the working mode, the travel speed changes by travel mode, and working mode.Flow Chart] 3-Speed Travel and Flow Cut | Travel motor switeh No Engine starts? > Yes | Low + Miade _Z No I Se To next process ® ous0n oun orF Tonext process: —35—@_ Soft/Hard Switch Circuit Diagram’ | | I Soniiard jk 1 om 8] TH] z pay sclenot valve | our of FLV eas WU) UU [Time Chart| on, Key switch -| 2B rq ese] we. ny ote em ot yl | a [ SOFT HARD SOFT | WARD Flow Chart] Soft/Hard Switch ‘Output to the softhhard solenoid valve is OFF No ~ when key switch is ON. This is SOFT status Engine starts? ‘After the engine is started, the signal received ves {rom the panel switch is changed. Then the signal oo of IN1 tums to LO, and 24V is output to the j Nt solenoid valve from the controller. When the sole- noid valve switches, hard status results. To nex’ process —3—Power Supply Cut Delay WY our nay Alternator Battoy relay ‘COUT 2 (WG) = 8 ir | Time Chart ‘ON wav om 4 V}— wp — 244) po eh our 2 ‘Power cut 24: V}—— ste [as] When the signal (IN1) from the key switch is turned OFF, 24V from OUTS is output from the controller for 8 seconds. After 3 seconds the output of QUTS stops, and power to the excitation coil of the electric battery relay stop, contacts on the electric battery relay break, and the power supply is cut.Flow Chart] Power Supply Cut Delay on Key SW Orr no 2 step.or Yes TERA? ‘upaton STEP-=0 set ves = Timer set No ouput OFF ater 3 s00.? (00) * ves —— STEP=1 set ouput ore STEP =2 set Tonext process@® Swing Brake/Swing Lock (1) Swing Brake 1) Engine is running and swing lever is in neutral (50% brake). lason chow oe 2] Sepuies Pate sot |e} 50% fade —Swing Tak — = | sows ub | poem Swing Brake] [Lever tock - \ (Swing b SOU :3 Swing shut of Free swing ‘switch rT ian Accumulator Swing lever ] ] i SOL :2 ‘Swing | Swing lock | Free swing |SOL:1 |S0%2 —|soL:3 | Monitor reer | SW ‘SW |100% tock |50.% | Shut of © OFF OFF OFF orr | ON OFF 24V is output to the swing brake solenoid valve (SOL:2), the pilot pressure which ran through the pressure reducing valve enters the swing motor, and brakes it by a force of 50%.2) Engine is running and ewing lever operation (brake release) Brake release -—s he Sing ack Pecon som wich Se PE swing ack tl roy sow:2 Wontar Swing Brake Laver lock Accumator eumng| 4 sows) Swng shurot Free sing Sitch swingiever| = 1 | Pressure switch RaoF ver| Swing ock |Freeswing|SOL:1 |sOL:2 — |sOL:3 | Monitor Swing tever| “SW SW.” | 100% lock [50% brake [Shui | (®) or | of [ om | oF | ON | oF j - ‘a a| ON | off | ofr | ofr | OFF | OFF q q ~ - 3 ale ever 7 ~ »)| ore | ofr | ofr | ofr | OFF } | ON | | i J | a) In operating the swing lever, the signal of the pressure switch enters the controller, and output to the swing brake solenoid valve (SOL : 2) is turned OFF. Pilot pressure enters directly, and the brake is fully released. b) In returning swing lever to neutral, the signal of the pressure switch goes OFF. The computer the outputs 24V on the swing brake solenoid valve (SOL :2) and after the 5 seconds deley the brake operates at 50%.(2) Swing Lock (Swing Lock Switch ON, 100% Brake) Brake 100% — ‘Swing lock eduction — 5 | Sach On A sou Swng oak Ho) Soe one Swing Brake fiero | Accumulate = Siig b = souv:3 Swng aro Hi Free suing tc Swing over 7 T sou:2 |sou:s \. Swing lock | Free swing | SOL: 1 . Swing lever] Swing lock |[Freeswing |SOL: 1 |50% | Shutoff Monitor brake |S 0c at Sw or | ON | of | ON | ON | ON | © When the swing lock switch is turned on €) 24V is output to the swing shut off solenoid (SOL : 3) and the solenoid valve shifts. Pilot pressure enters both ends of the swing section of the control valve, and the pilet pressure is than shut off instantly. (spool of control V does not move.) b) After 5 seconds, 24V is output to the swing lock solenoid valve (SOL : 1) and the solenoid valve shifts. Oil within the brake piston of the motor flows to the tank. The brake locks by torque of 100%. ©) Also 24V is output on the swing brake solenoid valve (SOL : 2) and the solenoid valve shits. a(3) Swing Free Swing (OPT) and Swing Lock ‘Gen KO o r ‘Swing lock Reduction suv _1.| — Pet sae oe Sater 1 [®] Far ‘Accumulator oie . b eh - aa ‘Swing shot off g LE Free swing Ai “ice ‘Swing lever f “1 sot.2 vat meget FE ay (Sat Mente ON oF ON OFF OFF OFF + | Sec. aner SW te fi ON | ON/| ON| Oy | | ON, © By turning on the swing lock switch while in free swing, the free swing output is stopped (not iilustrated) instantly, and the shut off solenoid valve is tumed on (SOL =3), and it shuts off low. After 5 seconds, the swing lack solenoid valve (SOL : 1) is turned on, and itis locked by 100%. In case of “Free swing”, Hyd. citcuit has an orfice so that swing speed and swing inertia are reduced by this orifice, -a2-—Flow Chart] Swing Brake FLAG-0 set Output OFF Brake releaseFlow Chart] Swing Lock Initial: STEP=0 7 yn ‘Swing tock SW i oN ‘Swing shut off ‘Swing shut off valve! Valve ‘ON ‘OFF J n Free swing output Free swing stop ns stoppe3 velease t No, ‘STEP-0? Yes 1 No, Timer set STEP=0 set . STEP=1? (sec) Yes No 5 sec. passed? Yes Timer clear . | — a tl Output On Output OFF | 00% lock Frolease lock ul To next process |@ Lever Lock Circuit Diagram Panel switch Lever jock] PBI ‘witch Time Chart| 2ay ON aay Gate lock Controier Spring up = Lever lock solenoid valve Monitor OFF oO} [1 __Locr wi TD IND 2Av Monitor~Flow Chart Lever Lock Spring us Spring uy Gate lock Running postion Spring up ‘unaing postion oN Controller function Lever lock Sw i ‘Output ON ower | Lever tock ‘Lever lock release — 46 — 4@ Travel Warning Circuit Diagram Travel plot pressure switch, ore Lf ‘Travel lever operation A travel pilot pressure switch is turned ON by travel lever operation, and 24V is output for 10 seconds to the buzzer. -a—@ Power Transistor Protection Controller Address! 8| Spare _ 7) Spare —6| Spare ‘Swing shut off solenoid V Lever lock solenoid V Travel alarm Prossure raising solenoid V Free swing solenoid V Negative control solenoid V Spare Spare SoftHard change solenoid V | Max. flow cut solenoid V ‘Swing lock solenoid V Warning lamp Boom lowering speed regulation solenoid V Travel 2-speed change solenoid V ‘Suing brake solenoid V Heating relay | Battory relay Ha solenoid valve or relay is shorted, it stops the output of a power transistor in order to protect the controller. “Electric system abnormality” is indicated at this time in message display. By performing a self check, the address of the abnormal place is indicated. Based on the address, check wiring and components. 48 —@® Monitor Display Radiator Water Temperature Circuit Diagram Over heat switch = 7 im Monitor yermo sensor | cru Thi Le | A/D i> wonrorerre “ Vottage 3.4-— 12 . a8 0 310 2350 Water temperature ("C) Resistance 1. OM.SW. and the ON signal of the thermostat sensor are OR processed and No. 8s it 2. O/H.SW. and the OFF signal of the thermostat sensor are AND processed and No. 8 turns oft 3. No, Bis iton the condition No. 1-7 are it. “4, When No. 1-7 are turning off if the ight-up signal of No. 8 enters, they light-up by 30 second delay in ‘order starting with No. 1. 5. No. 7 is put out on the condition that No. 8 is turned out. 6. When No. 8s it if the lights-out signal of No. 7 enters, lights-out signal of No. 8is waited for. 7. When No. 8s i, "OVER HEAT is indicated Values in chart below are design median ‘a OW OFF Over heat ewteh vite Toi ow 5 lore Y_Theimo sensor 18 { 96 120 7 FE ___* Hs on 3 co hes a ow 5 33Hydraulic Oil Temperature Circuit Diagram! bent 7 | mmm (a fe oe Monitor ! ‘Thermo sensor | ecru) |ivF) | . ™ n 4.0) 8000) | ri 4501 | |. Px] 110 450 8000 4. OMSW. and the ON signal of the thermostat sensor are OR processed and No. 8s it 2 OJMSW. and the OFF signal of the thermostat sensor are AND processed and No. 8 tums oft. 3. No. Bis lton the condltion No. 1=7 are it <¢ When No, 1-7 are turning of it the ight-up signal of No. 8 enters, they ight-up by 30 second delay in ‘order stating with No. 1 5. No. 7is put out on the condition that No. 8 is turned out 6 When No. 8s Itt the ights-out signal of No. 7 enters, ights-out signal of No. 8 is waited fr. 7. When No. 8is it, OVER HEAT" indicated Values inchartbeiow ae design median 88 on [ore overheat sen Poe SST Soy 8 lore therm sensor os__fF 110 7 lore i orF 6 i 5 fre | ore 43 a5 * _ on ss ot . 1 : a 1 aC 7Fuel remaining Circuit Diagram i | ru eve Monitor uel level sensor cpu Lt A/D Vr /] | i fad L Resistance 80 why 0.41 ( { i | I Fu Pry 10 Fuel Resistance (OHM) Values in chat below are design median SH00, 120 sH200, 220 Resistance| Resistance FUEL TANK | Amount (L) (OHM) | Amount (L)_ (OHM)| MONITOR: j215- 13-10} 284- 13-10 8 181-215 21-13 | 243-284 21-13 | 7 147~181 27-21 |200-243 27-21 6 192-147 (34-27 | 158-200 34-27 8 77-112 44-34) 115-158 44-34) i ra se-as| 72-115 sous] 8 (25-43 78-59) 39-72 78-59 | ? 1 ouret 25 80-70] -29 80-78| | Rotel siWarning Display (Message Display) START Message Display | (CkeySwON) —(RySWONA Engine Rumning) !Overheat {Battery charging Deficient 1 Electric system abnormality {Engine oil pressure down 1 Refuel Air cleaner clogged ves | Refill coolant Engine fiter clogged | 1 ——+| ! Engine emergency stop Replenish battery fluid NO ‘ding | Free swing Auto warm-up, Engine warm up ‘One-touch digging force up kt — H: Heavy mode L S: Standard mode L: Light mode F :Fine mode Note) 1) if more than one display instruction are set. They was be indicated alternately every 5 seconds. 2) When AUTO GLOW warm -upis finished, buzzer is sounded for 3 seconds. Ratuel Fue! efit cootant [Refew coolant as indicated iow. Check, and supply cooling water. unt Indicated if low. Check, and supply fue | Engine emergency stop [Engine emergency stop (emergency stop switch “ON’)is displayed. plenish battery fd | Battery liquid indicated if ow. Check, and replenish battery liquid. |i cleaner clogged | Alr cleaner element Is clogged. Wash or replace element. | Engine ol fiter is clogged. Replace an engine ol fiter. (When replacing engine of Engine fter clogged | ter, also replace engine of) Engine coolant or hydraulic ll temperature is high. Tum engine to lw iting, Over heat Tower the water or ol temperature J I] [Fayre otoressue | posse of engine oon, Chek engine i uantiy, and eles ow a RANE Sey Dy S382 P99 D6 prmormal charging system is dplaed. Check he elec ckeut ! Deseo [ears oe se Go ant roan aa Chek aes | ad ra eran